Method of and machine for forming metal



v 4 Sheets-Sheet 1 wm mh/fl a 9 "c. G. HAWLEY METHOD OF AND MAQHINE FOR FORMING METAL Filed Oct. 23, 1920 gags: W

April 1 ,'1924.

WITNE$ ATTORNEY-H April 1 1924. 1,488,494

C. G. HAWLEY METHOD OF AND MACHI NE FOR FORMING METAL 1 Filed Oct. 23 1920 4 Sheets-Sheet 2 INVENTOR.

fix) ATTORNEY.

,OODOO 00090060000 0 O O O O WITNESSES HM April -1,,- 1924.

C. G. HAWLEY METHOD OF AND MACHINE FOR FORMING METAL 1 52- '53 am -1 M 50 I WITNE S SE SI Fetentecl Apr. 1,

srara CHARLES GILBERT EA'WLEY, OF CHICAGO, ILLINOIS, ASSIGNOR T LOCOMOTIVE FIRE- BOX GOIvIPANY, OF CHICAGO, ILLINOIS, A CORPORATION OF DELAWARE.

METHOD OF AND MACHINE FOR FORMING- METAL.

Application filed Gctober 23, 1920. Serial No. 419,128.

To all whom it may concern:

-Be it known that 1, CHARLES GILBERT lnwtnr, a citizen of the United States, and a resident of Chicago, county of Cook, and State of Illinois, have invented a certain new, useful, and Improved Method of and Machine for orming Metal, of which the following is a specification.

My invention relates generally to machines for forming, bending, folding, and shaping heavy metal sheets, such as parts of steam boilers; and has particular refer ence to a machine for making Nicholson thermic siphons.

The general object of my invention is to provide a machine of a type which will lend itself to the forming, folding and shaping of a wide variety of articles.

It is also an object of my invention to provide a machine which shall be simple in construct-ion, of low cost, and which shall be simple and durable in operation.

Again it is an object of my invention to provide a machine whereby large heavy sheets can be formed, folded or shaped without the necessity of resorting to the formation of large, accurate and expensive dies for use in conjunction with heavy hydraulic presses, as has heretofore been necessary.

My invention consists generally in the form, arrangement, construction and co-operation of the parts, whereby the above named objects, together with others that will appear hereinafter, are attainable, and my invention will be more readily understood by reference to the accompanying drawings, which illustrate what I consider, at the present time, to be the preferred embodiment thereof.

In said drawings:

Figure 1 is a perspective view of a ma-. chine embodying my invention.

Fig. 2 is a transverse vertical section through the machine, but illustrating the 'working parts in a position different from that shown in Fig. 1.

Fig. 3 is a diagrammatical plan view of a part of the machine and the sheet metal conveying means.

Fig.4 is a detail transverse sectional View of the forming parts of the machine illustrating a formed sheet therein.

Fig. 5 is a sectional detail view substantially on the line 5-5 of 4-.

Fig. 6 is a detail sectional view of the parts shown in Fig. 4 except that the. folding wings thereof are in elevated position and the metal sheet is omitted.

Fig. 7 is a detail fragmentary View illustrating the means for holding the wings of the machine against shifting.

Fig. 8 is a detail sectional view illustrating the means employed to hold the metal sheet against shifting.

Fig. 9 is a detail view of one end of the metal pinching or forming member for use in the formation of a special shape or article.

Fig. 10 is a transverse sectional view illustrating the action of the pinching bar or member shown in Fig. 9.

Fig. 11 is a detail sectional view showing means for holding the inching chains free of the horse or mandrel. I

Figs. 12, 13, 14 and 15 are transverse detail fragmentary sectional views illustrating different modifications of'machinesembodying my invention.

Fig. 16 is a fragmentary plan View of that form of my invention shown in Fig. 15.

Fig. 17 is a plan view of a mandrel for use in making an article of manufacture (Nicholson thermic siphon) by a machine embodying my invention.

Fig. 18 is a partial elevation of the mandrel shown in Fig. 17.

Figs. 19 and 20; 21 and 22; and 23 and 24 are, respectively, plan and fragmentary elevations of differently shaped mandrels that can be used with machines embodying my invention and Figs. 25 to 36, inclusive, are fragmentary end views of different formations or shapes illustrating the adaptability of a machine embodying my invention to general manufacturing purposes.

My machine is adapted to a wide variety of uses and may .be employed advantageously for the manufacture of many arti siphons are of considerable size and the sheet of boiler plate necessary to its formation is quite heavy. The machine here illustrated is, therefore, of large size.

As here shown, I provide a pit 1, and an elevated foundation or floor 2. In the pit, 1, I vertically position a horse or mandrel 3 having its bottom portion 4, firmly anchored or secured in the floor or bottom 5, of the pit. The upper part of the horse or mandrel 3, extends above the floor level 2, and, as here shown, terminates in an enlarged substantially cylindrical ridge portion 6. The shape or contour of the horse or mandrel 3, is substantially such as is desired in the finished article.

Positioned over the horse or mandrel 3, and, as here shown, at right angles thereto, will be found two spaced structural metal beams 7 and 8 which are spaced apart, and which are supported upon suitable pillow blocks or pedestals 9 and 10, and 11, and 12, respectively. The structural beam 7 projects beyond the pillow block 10, terminating adjacent the hoisting mechanism, 13,

which, in turn, is mounted upon a base 14.

As here shown, the hoisting mechanism comprises a hydraulic engine 13 provided with pipe connections 15 and 16, having control valves 15 and 16 therein, and with a piston 17. A piston rod 18 is connected to the piston at one end, and at'the other end extends through a stufling box provided in the closed end 19 of the engine 13. The outer end 20 of the piston rod is normally restrained by a latch or stop dog 71 for suddenly releas ing the hereinafter described gravity weights or forming wings. The end 20 of the rod is connected to a chain 21, which, in turn,is secured to a drum 22 that is mounted for rotation with the shaft 23. The shaft 23 is supported in suitable bearings carried by the structural beams 7 and 8. Another shaft 24, paralleling the shaft 23, is likewise supported in suitable bearings mounted upon the structural beams 7 and 8. It will be noted that the centers of the shafts 23, and 24, are positioned upon opposite sides ofthe horse or mandrel Mounted on the shaft 23, for rotation therewith, will be found drums or pulleys, 25, 26, 27, and 28, whereas on the shaft 24 will be found drums or pulleys 29 and 30. A chain31 is secured at one end to the drum 25; a chain 32 to the drum 26; and chains and 34, respectively, to the drums 27 and 28. The oppo site ends of said chains are secured, respectively to lugs 35, 36, 37, and 38, which, in turn, are rigidly secured to the wings 39 and 40. These are heavy weights. They are hinged or tied together and do their work by falling or dropping upon the sheets to be folded. The wings 39 and 40, as will be better understood shortly, are suspended by means of the chains just referred to. Likeand 50.

essee-i wise these chains are utilized to control the dropping thereof and also for their elevation or restoration to their inoperative or horizontal position. 1

As illustrated in Figs. 1, 2, 3, 4, 5 and 6, the gravity acting wings are composed of metal sheets or plates 41 and 42, the inner faces of which are provided with wooden liller planks 43 and 44, respectively. Spaced somewhat from the contiguous edges of the plates 41 and 42 I provide elements 45 and 46, (conveniently called hinge blocks) which are rigidly secured to the plates 41 and 42 as by means of bolts 47 and 48. They are likewise further secured against shifting as by means of the dove-tail construction 49 The wings 39 and 40 are tied together against undesirable separation in a horizontal plane by means of the hinge chains 51, which are attached to the hinge blocks as shown at points 51. These chains obviously constitute I pivotal connections which permit the wings to hinge or swing between horizontal and vertical planes and return. Likewise, secured to the wings, as by means of bolts 52 and 53, will be found pinching chains 54. It is desirable, though not essential, that the links of the pinching chains 54 be supported against falling, While the Wings are in their horizontal posit-ion, and to this end I prefer to provide each thereof with a supporting spring 55, best shown in Fig. 11.

1 preferably provide the hinge blocks 45 and 46 with the removable parts 56 and 57, respectively, which parts I call pinching bars, as they set directly against the sheet under action and with the mandrel govern the form imparted to the sheet or plate by the operation of the machine.

It is believed that the remaining parts of the machine will best be understood by a description of its operation. To this end, I shall describe the movement of the wings and their action upon the metal sheet or plate.

A metal sheet or plate 58 to be shaped or formed is conveyed into a position adjacent one end of the horse 3, and on a level with the top of the mandrel, 6. At opposite ends of the plate 58 and centrally disposed therein will be found centering pins 59 and 60,

each having a lower end or head portion projecting from the under face of the sheet, and marked 60 in Fig. 8. In practice I prefer to move theplate 58 on a car 61.

groove. The plate 58 is then moved longitudinally of the mandrel or horse until it occupies a position substantially as shown by dotted lines in Fig. 3; in which position the other centering pin, 60, will also have entered the centering groove 63 in the mandrel Thus the sheet is centered on the mandrel and cannot escape or move from its proper position so long as the temporary guide or centering pins 59 and 60 remain in the mandrel groove. Columns or posts 64: and 65 (hereinafter termed spot-ting columns), respectively, are secured at their lower ends to certain of the hinge chains 51, the plates 41 and 42 being notched or cut away, as indicated at 66 (Fig. 7) to accommodate them. The upper ends of the spotting columns are vertically slidable in guides 66 secured to the machine frame. The spotting columns therefore prevent any swaying or shifting of the heavy wings with respect to the underlying plate and mandrel.

Reverting to the beginning of the opera-- tion, it will be understood that a plate cannot be put in or upon the machine until the heavy wings have been elevated to the position shown in Fig. 2 herein. The manner in which the plate is positioned in the machine, that is, in a horizontal position upon the mandrel, has been clearly described and is clearly shown in Fig. 2, wherein the plate is marked 58. During all of the time'that the plate is being put in position the wings are sustained by the winding mechanism before described and directly by the engagement of the latch 71 with the dog 70 on the end of the piston rod 18, which here represents the motive power device for lifting the heavy wings. The piston 18 is operated by air or water admitted to the cylinder 13 under pressure. When once the piston has been driven to the position shown in Fig. 2 so that the latch 71 may be engaged to support the falling wings of the machine the air or water is promptly allowed to discharge from the cylinder 13, leaving it virtually empty. This is accomplished by manipulation of the valves 15' and 16. Now all is in readiness for the actual folding operation on the sheet. This is brought about by tripping the latch 71 as by means of the falling weight 72. The weight of the hinged wings far exceeds the resistance of the piston movement and they therefore drop the moment the latch is released.

The settling of the weight of the wing on the plate serves to bend it, and obviously the accelerating fall of the heavy wings results in closing them together against the horse 3, as shown by dotted line in Fig. 2. This practice might be followed with a coinparatively thin sheet of steel as the article to be folded. In using the term thin I obviously refer to the relative bending strength of the plate and the weight of the wings which are allowed to fall upon it. In dealing with a relatively heavy or thick plate of steel and to avoid unnecessary jars and shocks, I prefer to start by first positioning the plate on the mandrel and then slowly lowering the wings by allowing the slow exhaust of air or water from the cylinder 13, making no use of the latch 71 at hat time. The first action of the wings, lins allowed to slowly settle on the plate,

r o bend the plate so that its two sides oi L halves are bent at about right angles to one another. This having been accom plished, the wings are again lifted by means of the motor (cylinder and piston in this case) and then the latch is made use of to hold the wings in suspended position until the cylinder 13 can be emptied. -When opposition to return movement of the piston 17 is thus removed, the latch 71 is lifted or tripped and the heavy wings are allowed to drop on the partially bent plate. This movement may be repeated as many times as may be necessary to complete the folding of the plate aroundthe mandrel and horse. In practice very few such heavy blows are required. 7

I now call special attention to the relative functions of the hinge chains 51 and the pinching chains 54 before described. When the wings are first lowered or allowed to drop upon the underlying plate the hinge chains come to rest upon the top ofthe plate, which, with the enclosed man drel, manifestly becomes the pintle of the great hinge. Obviously from that moment the hinge chains support the weight of the downwardly swinging wings, leaving the latter no motion except the downward swinging motion. Ultimately the inner sides of the wings press against the opposite sides of the sheet, and when this moment arrives there is a tendency to straighten the hinge chains. That is, the hinge chains alone would not prevent the wings from moving apart at the top. It is at such moments that the pinching chains come into action and serve to hold the inner or upper ends of the wings together and to convert each wing into a lever, of which the pinch chain is the fulcrum and the pinching bar 56 or 57 is the pressure point. It follows that a sort of nut cracker action takes place, due to the heavy momentum of the downwardly swinging wings, all of which, under the restraint of the pinching chains 54, is momentarily transferred to the faces of the pinching bars 56 and 57. By this action I accomplish the sudden underbending of the heavy sheet as well depicted in Fig. 4. Without the pinching chains or mechanical equivalent this efiect could not be obtained from the force of the downwardly swinging weights or wings.

Ample adjustability for the reception of plates of different thickness is provided by the threaded nutson the ends of the pinch chain shanks 52 and 53, whereby the pinching chains may be lengthened or shortened as required. Similarly, the thickness of the pinching bars 56 and 57 may be altered from time to time, either for the purpose of accommodating plates of different thickness or to form plates in different shapes. it will rarely be necessary to modify the. lengths of the hinge chains, although, as depicted in Fig. 12, I have pr vided means to that end.

From this description it will be quite apparent that I am able in a very few minutes to fold the great. sheet of steel from which a Nicholson therinic siphon is formed. The pre-shaped sheet clearly appears in Fig. 3 and the cross-sectional shape thereof, when folded, is well shown in Figs. 4, 8, and 10. When a sufficient number of blows have been struck by the wings they are elevated and locked in elevated position and thereupon the folded sheet is pulled off of the mandrel and horse, the same sliding longitudinally thereon.

A detail of the hoisting engine or cylinder comprises an arrangement by which the extreme forward travel of the piston is cushioned in the end of the cylinder by the fluid therein, the movement of the piston rods and chain 21 being checked at about the moment that the wings reach the dotted line position of Fig. 2. Over-running and back-lash of the hoisting chains and drums or sheaves is prevented by this simple measure of pushing or checking the let-go action of the hoisting motor or engine. Obviously either a steam, air or electric hoist with an interposed clutch could quite as well be substituted for the slower hydraulic hoist here depicted.

Though the wings weigh many tons, a hoisting motor of from five to ten horse power capacity furnishes ample power for the manipulation of the wings. This should be compared with the enormous expenditure of power in any hydraulic press which might be employed as a substitute for the machine herein depicted.

In the illustrative article, i. e. the Nicholson thcrmic siphon, it is desirable that one upper end portion shall terminate in straight downwardly and inwardly inclined portions instead of following the cylindrical form of the top of the horse or mandrel as in the major part of the article. This desired result I secure by cutting away parts of the pinching bar faces 56 and 57, thus forming the triangular flat face portions 56' and 57. As there is nothing to force or pinch the plate inwardly beyond the face portions 56 and 57 the desired straight downwardly and inwardly extending portions 75 result. These face portions may be termed relief faces or portions as they function to relieve the pressure upon the contiguous parts of the plate or sheet.

In Figs. 12, 13 and 1 1, modifieu constructions of the folding wings and connecting members are shown. Thus, in Fig. 12 the wings 76 and 77 are held together (their separation prevented) by means of pinch blocks 78 hingedly secured to one of the wings by means of the hinge 79. Also the hinge chains 80 are brought diagonally through the wing plates and made adjustable instead of being secured in the manner shown in the figures first described.

Fir. 141- shows a construction similar to ti. t snown in 12, except that the hinge chains 81 pass at right angles through the wing plates 82 and In all of the forms, thus far described, the wings have been provided with filler members usually taking theforni of wooden planks placed under the hinge blocks. My invention is not limited to any such construction, however, and Fig. 13, illustrates an embodiment wherein. the filler planks are omitted. In that form the metal plates 84: and 85 of the wings have bracket members 86 and 87 firmly secured thereto and upstanding therefrom. The pincher blocks 88 engage these. brackets functioning the same as those parts which directly engage the wing plates of Figs. 12 and 14:. The hinge chain 89 is shown as taking the form described with rcfcrenoe to Figs. 4 and 6, although this obviously may be modified if desired.

In Figs. 15 and 16, I have illustrated a construction such as serves admirably when the top of the Nicholson thermic siphon, or other article, is of varying contour or shape, as for example, when it tapers from one size at one end to another size at the other, as shown by the mandrel in Figs. 19 and 20; or where it tapers from one size at one end, to a smaller size in the middle and thence follows along straight lines to the other end, as shown by mandrel in Figs. 21 and 22 or being straight throughout most of its length,

terminates at one end in corrugations, as in dicated by mandrel in Figs. 23 and 24.

lVhen such variation in form is desired the top, 90, of the mandrel or horse varies in cross-sectional size and shape and the problem is that of bringing or shaping the metal to mandrel form by the mere falling movement of the Wings. This I accomplish by connecting the wings 91 and 92 by means of a plurality of chain links 93, the under faces 941 of which follow the curvature of the ad jaccnt portion of the mandrel. That is to say the various links of the chain are of dif ferent sizes and shapes, as may be necessary to conform to the particular mandrel or horse with which they co-act. Thus by hav ing the mandrel of tapering form throughout its length and the various chain links of reac es progressively increasing thickness, a true and accurate taper can be readily imparted to the article. It will be obvious that this construction also admits of the ready formation of the dithzrent shapes shown in the other views of the drawings, as well as such. other shapes and forms as may be desired.

It should also be obvious that the examples of dilferent forms of articles shown in Figs. 25 to 36 inclusive, can be formed by the use of my machine.

The head or top 6 of the mandrel or horse is made readily removable, thus facilitating the conversion thereof for the manufacture of Nicholson thern'iic siphons or other art-i cles in which the top or upper part only varies in size, shape, orconfiguration. Having the variables of the mandrel top portion, which is removable, and the pinching bar faces which likewise are removable, the ma chine can be very quickly and inexpensively changed from time to time as may be necessary to manufacture a wide variety of articles.

Inasmuch as this disclosure .will readily suggest to others skilled in the art to which this appertains, various modifications whereby the substantial objects and purposes of my invention may be attained, I do not wish to be limited to the specific construction herein shown anddescribed except only as may be necessary by limitations in the hereunto appended claims.

I claim:

1. A device of the class described embodying therein a mandrel having a portion that departs from the plane of other portions thereof, a swingable member, means for controlling the course of the swinging movement of the swingable member, said means including means conformable to a portion of the mandrel, and other means operative to force the swingable means into conforming relation to other portions of the mandrel.

2. A device of the class described embodying therein a mandrel, apair of swingable members, means for controlling the course of the swinging movement of the swingable members relative to the mandrel, said means including a hinge connecting the swingable members and a pinching element extending between and limiting the movement of the swingable members.

3. A device of the class described embody ing therein a mandrel, a pair of wing-like swingable members, means for controlling the course of the swinging movement of the wing-like swingable members relative to the mandrel, said means including a hinge connecting these swingable members and conformable to the contiguous portion of the mandrel, and a pinching element extending between and limiting the movement of the swingable members.

a. A. device of the class described embodying therein a mandrel, a pair of swingablc members, a flexible hinge connecting them.

a pinch tie connecting the swingable mem bers, pinch bars arranged on the respective swingable members, and means for control ling the course of the swinging movement of the swingable members relative to the man drel. I

5. A device of the class described embodying therein a mandrel, a pair of swingable members, a flexible hinge connecting them, it pinch tie connecting the swingable members,

pinch bars, having cut away pressure relieving portions thereon, arranged on the respective swingable members, and means for controlling the course of the swinging movement of the swingable members relative to the mandrel. I

6. A device of the class described embody ing therein a mandrel, a pair of 'swingable members, and means for locating and holding the swingable members relative to the mandrel, said means including a plurality of spot-- ting columns.

7. The herein described method of forming and shaping heavy sheet metal that consists in providing the sheet to be formed with centering projections, positioning the sheet overa mandrel having formed therein a portion for co-action with said sheet centering projections, and in dropping hinged wings upon the sheet and thereby conforming same to mandrel shape.

8. The herein described method of forming a Nicholson thermic siphon that consists in providing a5 mandrel having a substantially cylindrical upper ridge, placing a metal sheet in position with a portion thereof resting upon said mandrel, in dropping swingable members on the plate causing them to swing inwardly, and in the course of such swinging movement shifting the fulcrum, thereby causing a pinching of the sheet and a conforming thereof accurately to the curved outer face of the mandrel ridge portion.

9. A machine for folding heavy metal sheets with little expenditure of power, comprising an upstanding horse having a top of a shape to be given to the middle of the folded sheet, in combination with a superstructure and a pair of hinged-together Weights or wings normally hoisted and suspended from said super-structure at such distances above said horse as to permit the placing thereon of the sheet to be folded, said wings, when lowered, being adapted to fold upon said horse and interposed sheet, and the hoisting means whereby the wings are suspended from the super-structure being adapted to suddenly release the wings and allow them to fall upon the interposed sheet and thus fold it upon the horse.

10. A machine for folding heavy metal sheets with little expenditure of power, comprising an upstanding horse having a top of a shape to be given to the middle of the folded sheet, in combination with a superstructure, apair of hinged-together weights or wings, a hoisting mechanism whereby the wings are normally suspended from said superstructure at such distance above said horse as to permit the placing thereon of the sheet to be folded, said wings, when lowered, being adapted to fold upon said horse and interposed sheet and said hoisting mechanism being adapted to both slowly lower and suddenly release the wings and allow them to fall upon the interposed sheet and thus progressively fold-it upon the horse.

11. A machine for folding heavy metal sheets with little expenditure of power, comprising an upstanding horse having a bulging top or mandrel of the shape to be given to the middle of the folded sheet, in combination with a pair of hinged-together Weights or wings presenting under or inner surfaces generally complementing the shape of said horse and mandrel and adapted to fold thereover, a super-structure, a hoisting mechanism whereby the wings are raised and normally suspended from the super-structure at such distance above said mandrel as to permit the placing of the sheet thereon, pinching or restraining members which conmeet the wings inward of or above the hinged connection of the wings, and said hoisting mechanism being adapted to slowly lower the wings upon the horse and interposed sheet and being also adapted to suddenly release the wings and allow them to drop upon the interposed sheet and complete the folding thereof under the restraint of said members.

12. A machine for folding heavy metal sheets with little expenditure of power, comprising a horse having a sheet guiding groove in its top in combination with a pair of hinged-together heavy Wings adapted to fold over said mandrel, a super-structure vertically movable, spotting columns guided eas es in said super-structure and having their lower ends attached to the hinged connec tion of said wings and correctly positioning the wings over said horse, and a hoisting mechanism for raising and opening said wings and for lowering the wings by means associated with said hoisting mechanism for suddenly releasing the wings and allowing them to drop upon the horse, whereby an interposed sheet of met-a1 is folded by the force of the falling weights or wings.

18. A sheet folding machine comprising an upstanding horse and hinged-together wings adapted to fold on top of said horse, a superstructure, a hoisting mechanism for openingand raising said wings above the horse, means operatively connecting the hinged wings to prevent the swaying of the wings while raised, spotting columns secured to said means operatively connecting the hinged wings, means for guiding the metal sheet on the horse and beneath the raised wings and means for releasing the wings and allowing them to drop upon the interposed sheet and thereby fold the same over the horse.

14:. A. machine for folding heavy metal sheets with little expenditure of power, an upstanding horse having a bulging top or mandrel adapted to receive the sheet to be folded, in combination with two hingedtogether weights or wings normally suspended above said horse and adapted to be lowered thereon, means limiting the fall of the hinged-together ends of the wings when lowered and wing restraining or pinching' members which come into action as the wlngs approach the limit of the1r downward swinging movement, whereby the wings are caused to force the middle portion of the sheet into conformity with said bulging mandrel.

In testimony whereof, I have hereunto set my hand this 14th day of October, 1920.

CHARLES GILBERT HAWLEY. 

